INTERNSHIP TRAINING PROGRAM IN SAMBANDAM SPINNING MILL UNIT- 2 Definition: A person, usually a student, participating in a program of temporary, supervised work in a particular field in order to gain practical experience Objectives: The following objectives guide the Internship Program 1. An internship provides meaningful work experience, which supplements and modifies ideas gained from academic courses. 2. An internship enhances the student's subsequent academic work. 3. An internship offers the student an opportunity to assess his/her abilities and interests in management, thus assisting the student intern in choosing a specific career. 4. An internship provides an inside exposure to the structure, operations, and decision processes within an organization without a commitment to a permanent employer. 5. An internship places the student in a favorable position for permanent employment. COMPANY PROFILE: 1
Transcript
INTERNSHIP TRAINING PROGRAM IN SAMBANDAM SPINNING MILL
UNIT-2
Definition:
A person, usually a student, participating in a program of temporary, supervised work in a
particular field in order to gain practical experience
Objectives:
The following objectives guide the Internship Program
1. An internship provides meaningful work experience, which supplements and modifies ideas
gained from academic courses.
2. An internship enhances the student's subsequent academic work.
3. An internship offers the student an opportunity to assess his/her abilities and interests in
management, thus assisting the student intern in choosing a specific career.
4. An internship provides an inside exposure to the structure, operations, and decision processes
within an organization without a commitment to a permanent employer.
5. An internship places the student in a favorable position for permanent employment.
COMPANY PROFILE:
Sambandam Spinning Mill Limited was incorporated as a private limited Company on 7th Nov.
1973 under The Companies Act, 1956. The word Private was deleted under the provisions of Section 43A (2)
of the Act with effect from 1st July, 1989 when it became a deemed public limited company. The Company
became full fledged Public Company with effect from 17th June, 1994.
The Company has two units situated at Salem and Ayeepalayam. The Unit at Salem (Unit I) is
started in 1974 and is now having a spindle age of 45,000 spindles. The Unit commenced its commercial
production in May, 1974 with an installed capacity of 3,300 spindles. The spindle age was gradually
expanded in stages to 15000 between the years 1974 and 1980.
The expansion was financed by the way of Term Loans from Financial Institutions to the tune of
Rs.39 lakhs, Deferred Payment Guarantees of Rs.257.24 Lakhs from Tamilnadu Industrial Investment
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Corporation (TIIC) and State Bank of India (SBI). Further expansion programs were undertaken between
1980 and 1988 to increase the spindle age from 15,000 to 25,220. The capacity increase was financed by way
of term loans from SIPCOT, and also internal accruals.
SSML started with an initial installed capacity of 2,940 spindles. As on March 31, 2009, the group
capacity was 1,00,000 spindles spread between three units located in Salem district. The company also
has 17 wind energy converters for a total capacity of 12.80 MW in Tirunelveli and Coimbatore districts.
The Group of SSM includes,
Sambandam Siva Textile Pvt. Ltd
Sambandam Investment and Leasing Ltd.
S. Palaniandi Mudaliar Charitable Trust and
SPMM Healthcare Services Pvt. Ltd.
Sengunthar matriculation school(Trust)
The second unit at Ayeepalayam, Athanur in Salem District (Unit II) is started in 1990 with an
installed capacity of 5,760 spindles at a cost of Rs.335 Lakhs. The capacity was expanded to 12480 spindles
in 1993 at a cost of Rs.565 Lakhs. Both the above projects were financed by way of term loans from IFCI and
also internal accruals.
At present the Company has a combined aggregate installed Capacity of 28,000 Spindles.
MISSION STATEMENT OF THE COMPANY
The company mission is “ to strive for excellent in every sphere of company activity to give
best quality product which save the cost and time for the customer and best service, customer friendly in
fulfilling their requirements, aiming at steady development through up graduation of technology and
diversification for value addition”.
OBJECTIVES
To provide quality products to meet out the customer needs.
To provide employment potentiality to the local technocrats and laborers.
To maintain discipline of their public.
To conduct training classes for the labours on ISO 9000:2000 accident prevention and Labour
welfare in a phase manner.
Ensuring the total customer satisfaction
Increasing the value of the stake holders.
Development of processes and product
Compliance with relevant legal and other requirements
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Prevention of pollution and health hazards.
Continual improvements of organizational performance.
Involvement of employees / management at all levels.
ABOUT THE COMPANY:
Board of director
S.Devarajan- Chairman cum Managing Director
S.Jegarajan - joint managing director
S.Dinakaran - joint managing director
A.G.venkatesan
D.Sudharshan – whole time director
V.Mahadevan
P.S.Anthanarayanan
V.Gopalan
N.Asoka
Company secretary and chief financial officer
R.S.Shanmugam
Statutory auditors
M.S.Krishnaswami & Rajan
Cost auditors
S.Mahadevan & co
Bankers
State bank of India
Karnataka bank limited
Indian overseas bank
IDBI bank limited
Axis bank limited
Canara bank
Central bank of India
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Registered office
Mill premises
Post bag no.1
Kama raj nagar colony,
Salem 14, Tamilnadu.
Spinning plants
Unit I: Kamaraj Nagar Colony,
Salem 636014
Unit II: Ayeepalayam
Athanur 636301 – Namakkal district
Unit III: Kavarakalpatty, Seshanchavadi post
Salem 636 111
Wind energy converters
i) Uthumalai village V.K.pudur taluk
Tirunelveli district, Tamilnadu
ii) Panagudi pazhavoor and Parameshwarapuram villages
Radhapuram taluk, Tirunelveli district, Tamilnadu
iii) Gudimangalam village
Udumalpet Taluk, Coimbatore district, Tamilnadu.
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ISO 9001:2000 certified company
ISO 9001:2000 VERSION
It is stands for International Organization for Standardization.
It is given for a systematic process of an company.
Also given for continuous development and it s power of giving satisfaction to
their employees demand as well as unsafe able demands.
SSM product is known for 0% defects.
Benefits:
Products can set international giving
Can face the competitors
Standardized production
Giving importance in communication
Welfare of employee
Why it is need?
To decrease wastage and increase production and to give products with quality
QUALITY POLICY
Best, this saves the cost and time for the customer.
Customer friendly in fulfilling their requirements.
Up-gradation in technology and diversification for value addition.
MAJOR COMPETITORS
KKP textiles
SP spinning Mill
Premier group of Mills
Super group of Mills
Ram Co group of Mills
Jaya Jyothi Mills
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Management
Management puts a priority on people, communicates well, works hard, participates and is
constructive.
Management method makes employees feel that they are an essential part of the company
and helps them look to the future with optimism.
Employees are rewarding for their performance according to company policy.
Equal opportunities are offered in order to promote the skill and performances of the
employees.
Material and moral support and opportunities are provided to managers to motivate them to
reach their full potential.
Managers have the authority to hire or terminate employees.
KEY RESULT AREA SYSTEM:
As the key result key area SSM company follows,
100% production:
Company has more demands in domestic and as well as in the foreign markets. To satisfy
this needs company works for 24 hours and it leads to 100% production.
Quality
SSM exports 60 % of its production. It is a good example of its quality.
Customer satisfaction
SSM has runs from 1974. Without customer’s satisfaction it is hard to run the company
successfully.
Keeping all in standards:
From the department of Mixing to Packing everything after checking only moves to next
department.
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ORGANISATION CHART
Electrical Staff (Unit-1 & Unit-2)
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TRAINING – ELETRICAL
SUPERVISOR
HELPER
GENSET SHIFT
OPERATOR
SHIFT ELECTRICIANS
GENERAL SHIFT ELECTRICIANS
ELECTRICAL SUPERVISOR
TECHNICAL SIDE
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S.M
J.M (Main) J.M (QC) J.M (Production & Training)
Maintenance supervisor
Fitter
Quality investigator
Q & C
Electrical Supervisor
Production supervisor HED
Shift supervisor
EDP
HED assistant
Electrical assistant
supervisor
ADMINISTRATION
ORGANIZATION LAYOUT
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OFFICE MANAGER
COTTON CLERK
YARN CLERK STORE KEEPER LABOUR CLERK RECEPTION
STORE BOY
CIVIL E.D.P DRIVERS
CLEANERSEQURITY GUARDS
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1, 2, 3 –SECURITY ROOM
4 -TRANSFORMER II
5 -POWER HOUSE II
6 -GENERATOR
ROOM
7 -DIESEL TANK
27 -HUMAN
EXCELLENCE
DEPARTMENT
28 -YARN GODOWN I
29 -SUMP
30 -POWER HOUSE I
31 -TRANSFORMER I
32 -BUFFING ROOM
33 -COTTON
WASTAGES
34 -TESTING
DEPARTMENT
35 -TRAINING ROOM
36 -ADMINISTRATION
37 -STORAGE
DEPARTMENT
38 -DIRECTOR ROOM
39 -SENIOR
MANAGER
40 -PACKAGING
MATERIALS DEPT
41 -GARDEN
42 -LADIES
RELAXATION
ROOM
43 -GENTS DINING
ROOM
44 -LADIES REST
ROOM
45 -YARN GODOWN II
46 -GENTS
RELAXATION
ROOM
47 -BIKE PARKING
48 -REUSABLE
WASTAGES ROOM
49 -CIVIL DEPT &
SPINNING
50 -GARDEN
51 -GENTS REST
ROOM
52 -CANTEEN
53 -STAFF QUARTRES
54 -HED TRAINING
ROOM
55 -LIBRARY
56 -GARDEN
57 -WORKSHOP
58 -GARDEN
59 -GENERATOR
ROOM
60 -COTTON
GODOWN
UNIT - 1
8 -AUTO CORNER
9 -CONE WINDING
10 -SPINNING
11 -SIMPLEX
12 -COMBER
13 -CARDING
14 -BLOW ROOM
15 -PACKAGING
16 -DRT
17 -TFO
18 -DLG
UNIT - 2
19 -AUTO CORNER
20 - DRT, TFO
21 -SPINNING
22 -SIMPLEX
23 -CARDING
24 -COMBER
25 -BLOW ROOM
26 -MIXING
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HUMAN EXCELLENCE DEPARTMENT
IMPORTANCE:
Human resources are the most valuable assets of the company. To make them safe and
comfortable, Human Excellence Department (HED). HED is a very powerful one in the overall
management functions. Employees are controlled, satisfied in the SSM limited by this HED.
Recruitment
Selection
Induction
Training
Promotion
Functions of the HR Department:
Production budget preparation.
Fixing the work. Lead of individual workman.
Calculation of ideal time and over time stoppage.
Recruitment, selection and appointment.
Wage and salary administration.
Grievance handling.
Employment benefits measures.
Training and development.
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Procedure for Grant of Leave and Regulation of unauthorized Absence
A workman who desires to obtain Leave of Absence shall application for leave must be
made at least 24 hours prior to commencement of Leave. This shall not apply in the case of
emergency or serious illness.
Grant of Leave shall depend on the exigencies of work and shall be at the discretion of
the head of department or the company as the case may be
If Leave is refused or postponed, the fact of refusal or postponement and the reason there
of shall be communicate to the concerned workman.
If a workers desire extension of period of his \her Leave. He /She shall make an
application in writing well in advance before the expiry of His /Her Leave originally granted.
The sanctioning authority may inform the employee the result of His /Her Leave application.
In case the extension of Leave does not reach in time, the period between the expiry of
Leave and the receipt of the application made by the workmen shall be treated as absent unless
the company is satisfied that the delay in submission of application was due to some unavoidable
circumstance.
If the workman remains absent beyond the period of level originally granted or
subsequently extended He /She shall be deemed to have left the employment unless.
He /She return within 8 days of the expiry of the Leave and Gives a satisfactory
explanation for His /Her inability to return on the expiry of leave
Workman shall submit to the management ESI certificate within the time stipulated by
the Act and scheme framed there under Whenever ESI coverage is there. If the certificate is not
submitted in time Him / she is liable to disciplinary action under the standing orders.
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RECRUITMENT:
WORKERS RECRUITMENT:
The company staffs canvass the candidates of any qualification is the nearby. This type of
workers can work in production department.
Also the workers are recruited by display board outside.
STAFF RECRUITMENT:
Technical and office employees are high in demand.
Existing employee’s reference to their relation, friends and neighbors are considered. They
can be selected through personal interviews and verification by their certificates.
SELECTION PROCESS:
Preliminary test written test is conducted through pre-planned questionnaire to the
candidates.
UN-STRUCTURED INTERVIEW:
Are conducted and personal interviews to analyze their performance of the candidates in the
selection process.
The candidate’s skill and performance is tested by the interviewers.
Once the candidates appointment order is selected issued by the senior manager to the
To enable the continuous development of the skills of our employees and to improve
communication, training programs are prepared and applied in accordance with the targets of the
company.
Below kinds of training and application opportunities are given to employees to enable them
to develop personal skills such as competency, leadership and creativity.
i) IDENTIFY THE TRAINING NEEDS:
The existing employee’s performance will be analyzed by the HED and by his assistance to
know what are the actual needs of employees to improve their current performance.
It will helpful to the employees for their further improvements.
ii) CONDUCTING TRAINING :
After analyzing the training needs the needed training will be conduct to the employees.
This training program period depends upon the training needs.
iii) EVALUATE TRAINING:
After training given to workers after some weeks or month effectiveness of the training will
be tested through their process.
Employee training
|
New employee Existing employee
- Induction program - All training expect Induction
- First aid training training (Yearly once)
- Disciplinary training
- Quality management training
- Material handling training
- Humidification plant training
-Job oriented training
-Fire fighting training and
-Electronic Yarn clearer training.
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TRAINING OF NEW EMPLOYEES
The new employee must attend the various types of training programs as followings
1. INDUCTION TRAINING:
In the induction training, the origin of the company, vision, mission, objectives,
procedures, authority, working hours, rules & regulations and all the other details are explained.
By this the freshers are made comfortable to work in the new environment.
2. FIRST – AID TRAINING:
The employees are trained in such a way that if any accidents occur unexpectedly, the
injured person is given with first aid treatment and he is taken to hospital for further treatment
for the injuries. The first aid box is made available in all the departments.
3. DISIPLINARY PRACTICES TRAINING:
The company strictly follows the rules & regulations of the company. The same is
expected from the employees and the new comers. For this, the freshers are explained about the
rules & regulations of the company, how to respect other co-workers.
4. QUALITY MANAGEMENT TRAINING:
The Quality & Control team checks the product (cotton & yarn) as the product passes
through various departments. The corrections are adjusted then and there in each department as
the product is processed.
5. MATERIAL HANDLING TRAINING:
As for as the spinning mills is concerned, it fully deals with the machineries. The
employees needs to learn about all the technical functions of the machines and also how to
handle it.
6. HUMIDIFICATION PLANT TRAINING
Humidity varies by seasonal changes. To maintain the suitable humidity in cotton, the
employees are trained as and when the exhaust fan has to be switched ON and OFF.
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7. FIRE FIGHTING TRAINING:
The new employees are trained as how to use the fire & safety equipments so that the working
premises and human destruction can be avoided when disaster occur.
8. ELECTRONIC YARN CLEARER TRAINING:
New employees undertake EYC training. It will be conducted by HED department. All the new
comers will be under the supervisors of the respective department until the employees are trained
completely.
TRAINING TO STAFFS:
Internal quality audit
Leave and absenteeism counseling class
Personality development classes
Born to win class
EMPLOYEE DETAILS:
I shift - 7.30 a.m to 3.30 a.m – 200 employee
II shift – 3.30 p.m to 11.30 p.m – 150 employee
III shift – 11.30 p.m to 7.30 a.m – 150 employee
Total Employees: 500
HUMAN RESOURCE POLICIES:
RULES AND REGULATIONS:
Every employee should be inside mill before ten minutes of the shift.
Employee should wear only the company’s uniform and should avoid the other uniforms
when they are inside mill.
HR policy should be changed only by the authority of HED department.
LABOUR WELFARE FACILITY:
The company provides purified water to employees.
No sexual harassment
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If the employees get accident inside the company at once they will take to SSM’s sister
concern hospital (or) to the nearest hospital.
If the employees work for half overtime, the company is providing snacks and for full
overtime, the company is providing snacks with Tiffin.
Free bus facility is provided to the employees to take them from and to from their living
place.
Relaxation rooms are separately available for both gents and ladies employees.
Highly hygienic Rest rooms are available.
Mask, aprons and uniforms are provided for every employee.
Loans are provided for home appliances and two wheelers.
Canteen facilities.
GRIEVENCE:
ESI, BONUS, loans provided by the co-operative society and post office amount can be
claimed
Labor insurance can be claimed
The employee who has 5yrs of experience should be provided with the gratuity
Helping loans are provided for the employees’ for their children to pursue their higher
studies.
PERFORMANCE APPRAISAL:
During Ayutha pooja day, The “Best worker” of the company is appreciated with gift
hamper.
The employees are rewarded with the gifts for not taking leave in any of the working day.
FINANCE AND ACCOUNTS DAPARTMENT
Finance is the lifeblood of any business organization .It is concerned with allocation of funds
to various areas and obtained the best mix of financing in relation to the profitability of the company.
Financial System deals with all matters concerned with planning in term of money .
MAIN OBJECTIVES
The main objectives of the finance and accounts as follows
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To establish the amounts of funds required for achievement of the objective and determine
the obtaining funds
To ensure that the profits earned by the company are disposed of the best advantages of the
share holders and company
To achieve maximum efficiency in the enterprise through proper planning, organization,
control of financial resources.
To achieve and secure safely investment
To raise and maintain funds at the lowest cost possible
FUNCTIONS
The function of the financial department of SSM.
Collection all information’s from various monthly comparisons statement every month
Comparison of revenue accounts with the budget proposes.
Capitalization of fixed assets projects and calculation of depreciation for them
Preparation of bank reconciliation statement
Checking cash flow position
Verifying and making the payment for excise duty sales tax
Computation of deduction of tax at source ,filing of forms issue of TDS certificate
Tax planning and tax management of the company.
FINANCIAL RESULTS
The financial results of the company are prepared periodically and financial decision is taken.
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PROCEDURE FOR EFFECTIVE PAYMENT
In SAMBANDAM SPINNING MILL, the following procedure is being adopted in respect of
payment of bills
If a particular department is in need of any material or spare parts it has to intimate the material
purchase manager who before placing the order with the suppliers has a discussion with general
manager of funds and chief manager of accounts and finance and considering the financial position of
the company, approves the purchase of the needed materials and place the order with the he supplier
The supplier will send the goods of raw material to purchase department or stores department
along with invoice copy and LR which are checked with reference to quantity and quality of goods ,The
appropriate department puts a mark on the reverse as passed for payment to finance and accounts puts
his signature and passes it to general manager of funds for approval ,After the approval, the cheque is
drawn for the remittance of the amount to the supplier, some of the supplier to the company borrowed
money from banks to meet out their working against the security of the bill .In such cases the invoice of
the supplier are affixed with the bankers seal and the company has to make payment to the bank which
has lent the money to the supplier instead of payment it directly to the supplier.
Interest charges have been divided into three categories
Interest on Raw materials
Interest on term loans
Other interest charges
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Interest on borrowings against the security of raw material cost on the value of cotton consumed
for each year.
Interest in term loan is allocated in the various departments in the basis of written down value of
the fixed assets in each cost centre
Other interest charges are charged to the end products on the basis of the sales realization.
ISSUE DETAILS (In 2009)
Authorised issue – 50,00,000 equity shares of Rs. 10 each
Issue of 42, 86, 400 Equity Shares of Rs. 10/- each at par (Issue Price of Rs.10/-)
Dividend payout:
The board has recommended a dividend of Rs.2.50 per equity share for the year ended march 31st 2009,
absorbing Rs.124.73 lakhs including dividend tax.
The directors present the 35th Annual Report and Audited Accounts for the year ended March 31, 2009 (the year). Performance highlights 2009 2008 2007 TURNOVER - gross (Rs. lakhs) Direct export. 63 603 944 Merchandise export 2508 3281 2066 2571 3884 3010 Domestic 9351 8782 10048
11943 12684 13058 Less sales tax and cess recovery 266 246 252 Total turnover 11677 12438 12806
PROFIT21
Gross profit (ie. profit before interest and depreciation) 1796 2604 3326 Cash profit (ie. profit before depreciation) 466 1673 2585 Profit/(loss) before tax (537) 856 1309 Profit/floss) after tax (382) 592 1122
EPS Earnings per share - Basic Rs. (8.96) 13.88 26.31 Dividend payout Due to the loss incurred by the Company, the directors have not recommended any dividend for the year ended March 31, 2009. CURRENT SHARE RATE: Rs.91.08
COTTON DEPARTMENT
The main raw material of the company is cotton. The cotton is purchased in bales. It is mostly
purchased from both domestic and international markets. During the purchase the quality, count
and length are the main criteria they look for.
There are five cotton departments. They have the capacity to store 15,000 bales. Cotton is
imported from Rajapalayam, Pollachi, Coimbatore, Maharastra, Andra Pradesh, Guntur,
Singapore, etc..
TYPES OF COTTON:
Domestic: International:
MC5 GIZA
BUNNY LK
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MECH I PLEPE
BCH 32 MELBO
BOLO-S H6
RCH H4
COTTON PURCHASE:
PARTY PLACE TYPE AGENT
Balaji Trading
Company
Ramdurg DCH32 32mm U.G Raja
Mahalakshmi
Enterprise
Aurangabad Bunny 28mm Dhanalakshmi
Cotton
Terupati Enterprise Aurangabad MECH I 28mm Dhanalakshmi
Cotton
Sri Saiagnr Balaji
Agro Pvt Ltd
Adilabad H6 28mm Dhanalakshmi
cotton
PRODUCTION DEPARTMENT
SSML manufactures cotton yarn of various counts that range between 10s (coarser) to 80s
(finer) which caters to manufacturers of knitted and woven garments, home furnishing fabrics,
medical/surgical fabrics and industrial fabrics in both domestic and global market.
The Company has a sound track record of productivity and profitability, and has been producing
high quality yarn for the domestic market. The Company has also been regular in modernizing its unit and at
present almost all the machines at its existing Units are fully modernized. The Company's product range
includes cotton carded and combed yarn in the count range from 30s to 80s. The company's products are well
received in the local and international markets.
PRODUCT RANGE:
30s To 100s, 100% cotton yarn in the following varieties.
Karded /Combed.
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Ring Doubled/Two for one twisted
Ply yarn(3/4/6)
Auto Coned, Auto Leveled.
Siro cleared.
Double hank plain reel/gross reel.
Four hank plain reel/gross reel.
Yarn conditioned
Gassing yarn
TYPES OF PRODUCTION
SSM is very flexible in production as it follows the following production techniques so as
to cater to the needs of the customer.
Mass production:
Manufacturing of discrete parts or assemblies using a continuous process are called mass
production. This production system is justified by very large volume of production.
Flow of materials and components is continuous and without any back tracking.
Make to stock production:
The manufacturer stocks the finished goods in inventory for immediate delivery.
This system ensures immediate delivery of good quality, standard products.
SSM follows this system in 30s and in 40s count. Because they are normally in demand in
the domestic market.
Make to order:
SSM company also follows ‘Make to order’ production. That is company make or
manufacture products after the receipt of the firm order from the customer.
They opt for receipt for the 70s and 80s count.
Layout:
SSM follows the process layout in its working environment as everything in the
production is concerned with huge machineries.
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What is ‘process layout’?
Process layout is the arrangement of facilities that are grouped together according to their
function.
This layout is recommended for mass production. All machines performing similar type of
operations grouped at one location in the process layout.
PRODUCTION PROCESS
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S.N
o Departments Input
P
rocessing
Outpu
t
Number of
Employees
Working
(per shift)
1 Mixing Cotton
Bales
Tuft sizes of Cotton
bales are opened
through pre-opened
Contaminated
materials are
removed by a Team
of workers and Make
it as a Mixing with
Cotton with
removed
contaminations
40
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Blow Room
Carding
Sliver Lap
Ribbon Lap
Drawing
Spinning
Simplex
DRT
Comber
Doubling
TFO
Auto Coner
Packing
Cone Winding
small tuft.
Depends on weight
Laps are separated
(Basic weight 24kg)
Chute feed
2
Blow Room Mixed
Cotton
Converting the mixed
cotton to Lap stage
and by eliminating
the seeds, foreign
material, leaf bits
etc.,
Lap 2
3 Carding Lap Converting the Blow
room Lap to carding
sliver by eliminating
short fibers, seeds,
leaf bits etc.,
Sliver 3
4 Sliver Lap Cardin
g sliver
18 to 22 carding
sliver are combined
to make a sliver lap
Sliver lap 4
5 Ribbon Lap Sliver
Lap
6 Sliver Laps are
drafted and make it as
a Ribbon Lap
Ribbon Lap 4
6 Comber Ribbon
Lap
Converting the
Ribbon Lap into
comber sliver by
extracting the comber
noils (Removing the
short fibers)
Comber sliver 2
7 Drawing Combe
r cans
6 to 8 comber cans
are combined and
drafted to make a
Drawing sliver
Drawing sliver 2
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8
Simplex Drawin
g sliver
Drawing 120 sliver
cans are converted as
a thin material called
Roving with
sufficient Twist. It
takes 3 mins to finish
a bobbin
Roving
(Bobbin)
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9 Spinning Bobbin Simplex bobbin are
converted as a final
stage of yarn with
required draft and
twist
Yarn 13
10 Cone
winding
Cops Converting the cops
to cones by arresting
the yarn faults such
as Slub, Fluff, Thin,
Thick contamination
through advanced
yarn clearer.
Cones 11
11 Auto Coner Cops Converting the cops
to cones by arresting
the yarn faults such
as slub, Fluff, Thin,
Thick contamination
through advanced
yarn clearer
(All operations are
done by
automatically)
Cones
4
12 DRT Cones Converting the 2
single yarn cones to
one DRT Cheeses.
Cheese 4
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13 Doubling DRT
Cheese
DRT cheese
converted as a
Doubling Cops with
required twist
Doubling Cops 4
14 TFO DRT
Cheese
DRT cheese
converted as a TFO
Cones with required
Twist
TFO cones 4
15 Packing Cones Final Products are
checked under Ultra
Violet (UV) Lamp
and the non
conforming products
are segregated.
Materials are packed
in a carton box
(consists >20) (or)
pallet form (consists
>500)
Finished Goods 9
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YCP BOILING MACHINE:
It’s a heating machine which helps to heat the cones. According to the need of the customer the
required count of cones are heated using YCP. The ordinary cones will be flexible, after its treating
using YCP heating machine, the threads become stiff.
MARKETING DEPARTMENT
The company’s products are in good demand for the past several years. Hence no
difficulty is anticipated in marketing. The company entered into export market in a humble way
recently. This will be expanded to the best possible extend in future .The entire sales of the factory are
being directly controlled by joint managing director of the company with the two assistants of junior
officers.
They manufacture the yarn based upon the demand and the requirement of order. They
are fully capable to sell what they produced. They gained 5% of Salem yarn market, 10% of Nagari
market and 2 % of Coimbatore market. Their share in Indian yarn market is only 0.61%.
YARN SALES:
Yarn is manufactured by spinning unit and taking into current total market requirements,
exports order and yarn required for the weaving unit. Accordingly yarn is manufactured in opened, cut
the sophisticated order machines and through ring frames as per monthly production programmers
chalked out.
DIRECT SALES:
The sales concluded directly to the buyer from the seller without any mediator. The
company enters into a contract directly with the buyer. The goods must be sent to the buyer within the
stipulated period as per the contract. The contracts have been entered into the parties as per the terms
and delivery of goods and sending of invoices either directly or through bank will made. Another copy is
sent to accounts department. At the time of receipts of invoices, accounts department debits the parties
account and when the cheque is cleared credit the parties account. If due means periodical follow – ups
are made.
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YARN DISPATCH
Receipt of dispatcher advice
Inspection
Storage Preservation
Dispatch
INPUT/OUTPUT TABLE OF YARN DISPATCH:
S.NO INPUT PROCESS OUTPUT
1 Dispatch invoice delivery
challan
Check the quantity & packaging
specification as per stock
Finished stock
2 Inspection Based on invoice put the
central excise number and
batch number in the invoice.
At yarn godown inspection
status boards identifies
waiting for final inspection
ready for dispatch “NCP”
Gate pass final
inspection report
3 Finished product Finished product stock in
yarn godown.
Neat flooring condition
prevention from fire.
Fewer safe ventilators.
Suitable fire fishing
Preservation record
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instrument
Enough space
Prevention of fire hazardous
4 Dispatch Checking the condition of
lorry
Load of the goods to
lorry/container
Pesticides applied
Inside container before
loading
Delivery note
SWOT ANALYSIS
Strength
Value added products
More Export
Hard working employees
Brand name
They produced 100% cotton
Highly quality conscious
Long background – market presence nearly 50 years
Strong technical background
Ultra modern machinery
Trained work force
Government support on power failure
Weakness
Lack of employees
Workers getting stress by overtime
Opportunities
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Potential to export the products
Increasing of needs for quality products
Familiar company name in domestic market
Production of other fiber variety yarn (both natural and artificial)
Government support for technological development and trade.
Diversification of business into garment manufacturing unit.
Threats
This company’s policies may followed by other companies
Increasing competitors
Highly disoriented industry
MAINTENANCE DEPARTMENT
BLOW ROOM
S.No Process Frequency
1 Pedals cleaning &checking 3 months + 7 days
2 Gear box Oil change
Cone drum
P - IV Gear box
Lap unit
6 months + 15 days
3 Gear motor oil change 6 months + 15 days
4 Card bars changing 6 months + 15 days
5 Beater setting checking 6 months + 15 days
6 Top cone drum differential
gear box services
12 months + 30days
7 Sketcher front unit greasing &
pneumatics line servicing
12 months + 30 days
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CARDING
S.No Process Frequency
1 Full setting 3 months + 7 days
2 Doffer drive gear box oil
change 6 months + 15 days
3 Licker in wire change 12 months + 30 days
4 Cylinder Doffer and flats
grinding
9 months + 22 days
5 Oiler servicing 12 months + 30 days
6 Flat drive servicing 12 months + 30days
7 Wire mounting 42 months + 105 days
8 A product doffer unit servicing 6 months +15 days
Sliver lap & Ribbon lap
S.No Process Frequency
1 Costs Buffing 2 months + 7 days
2 Fultted roller eccentricity
checking
2 months + 30 days
3 Fultted roller setting checking 6 months + 15 days
4 Drafting unit checking &
servicing
12 months + 30 days
5 Pressure saddle hook setting 3 months + 7 days
6 Lap roller lap disc calendar
roller unit bearing checking
12 months + 30days
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COMBER
S.No Process Frequency
1 Draw box cots buffing 2 months + 7 days
2 Setting checking 3 months + 30 days
3 Gear box oil change 4 months + 7 days
4 Brush height setting 6 months + 15 days
5 Detatching roller cots buffer 2 months + 7 days
6 Machine servicing 48 months + 90days
DRAWING
S.No Process Frequency
1 Top roller cost buffing Twice/Months
2 Gear box oil change 6 months + 15 days
3 Gear servicing 12 months + 30 days
4 Bottom roller eccentricity
Checking & drafting unit
servicing
12 months + 30 days
5 Main drive, shaft, tension
puller bearing checking
12 months + 30days
SIMPLEX
S.No Process Frequency
1 Gear box oil change 6 months + 15 days
2 Top roller costs buffing 3 months + 7 days
3 Top arm pressure checking 3 months + 7 days
4 Roller cleaning red cleaning
& foot step oil change
6 months + 15 days
5 spindle drive shaft bobbin
drive shaft coupling checking
6 months + 15 days
6 Top & bottom apron change 18 months + 45 days
35
7 Main gear and service 2 months + 60 days
8 Drafting gear and mid
servicing flatted roller e
eccentricity checking and
servicing
24 months + 60 days
9 Top & bottom cone Drum
servicing
6 months + 15 days
SPINNING (Compact)
S.No Process Frequency
1 Elite mange tube cleaning &
elite tuber suction checking
elite apron cleaning (Ultra
sonic)
3months + 7 days
2 Top roller buffing 60 days + 7 days
3 Elite lattice apron checking 15 months + 30 days
4 Elite drive shaft bearing 3 months + 7 days
5 Elite tape tension pulley
greasing
3 months + 22 days
6 Elite suction tape changing &
centering
9 months + 22 days
7 Mango tube insert changing 24 months + 60 days
8 Intermediate gate gear
changing
24 months + 60 days
SPINNING
S.No Process Frequency
1 Costs buffing 2 months + 7 days
2 Top arm pressure checking 6 months + 15 days
3 Addition drive checking 12 months + 30 days
4 Delay drafting unit checking 1 months + 5 days
5 Spindle lappet garaging & 9 months + 22 days
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travelling
6 Spindle oil change 9 months + 22 days
7 Jockey pulley greasing 6 months + 15 days
8 Variator unit service 12 months + 30 days
9 Bobbin holder service 24 months + 60 days
10 Gear end, builder oil service 24 months + 60 days
11 Top & bottom apron change 18 months + 50 days
12 Tin roller beauty servicing 82 months + 210 days
13 Spindle tape change 18 months + 90 days
14 Rings change 48 months + 120 days
15 Spindle change 96 months + 240 days
16 Tin roller bearing greasing 3 months + 7 days
CONE WINDING
S. No Process Frequency
1 Drum shaft coupling checking 3 months + 7 days
2 Drum setting & Holder setting 3 months + 7 days
3 Tension device setting checking 3 months + 7 days
